Wave-like structures bonded to flat surfaces in unitized composites and methods for making same

Abstract

A simplified manufacturing technique to directly form a unitized composite structure with at least one relatively flat surface and at least one sinuous element in an internally-bonded unitized composite is provided. A matrix of fibrous and or other materials is deposited in layers which are subsequently formed into corrugated or wave-like shapes and exposed to an activation step. At least one element is composed of a contractive material which shrinks when activated, such as by heating in an oven, to become relatively flat and optionally bonded to at least one other non-contractive layer which remains in a sinuous shape after the activation step.

1. A composite comprising a structure having two or more layers, at least one of the layers comprising a sinuous layer and at least one of the layers comprising a relatively flat layer, the relatively flat layer comprised of contracted material fused to the sinuous layer. 
     
     
       2. The composite of  claim 1  wherein at least one layer is a previously made roll good material. 
     
     
       3. The composite of  claim 1  wherein at least one layer is an in situ produced nonwoven material. 
     
     
       4. The composite of  claim 1  wherein the at least one sinuous layer comprises two sinuous layers wherein each of said sinuous layers is located at each of two exterior locations of said composite. 
     
     
       5. The composite of  claim 1  wherein the at least one flat layer comprises two flat layers wherein each of said flat layers is located at each of two exterior locations of said composite. 
     
     
       6. The composite of  claim 1  having relatively open cavities defined between the sinuous and flat layers which can optionally contain particles. 
     
     
       7. The composite of  claim 6  in which the cavities contain particles, and wherein said particles are sufficiently localized to prevent substantial migration. 
     
     
       8. A composite of  claim 6  wherein the particles are carbon or mixtures of carbon and other particles. 
     
     
       9. A composite of  claim 6  wherein the particles are cement, plaster or similar materials which react to bond together when water or some other fluid or agent is applied to said particles. 
     
     
       10. A composite of  claim 6  wherein the open cavities contain particles and the particles are materials which can be caused to react at selected predetermined conditions. 
     
     
       11. A composite of  claim 10 , wherein the particles are selected from thermosettable, thermoplastic or cementitious. 
     
     
       12. A composite of  claim 1 , wherein at least one of the exterior surfaces has protruding fibers.